Replacing Headlamp Units of a BMW 2002.

Replacing Headlamp Units of a BMW 2002.
Tools required; Philips screwdriver. 13MM, 8MM spanner and/or socket. Pencil.
Headlamp reflectors often go rusty and the glass lenses can end up with stone chips and
cracks, this allow damp to enter the headlamp unit and over time the reflector will go rusty
effecting the quality and efficiency of the beam.
Below image the lenses is cracked just above the “Hella” name.
This image below, you can see the reflector going rusty at the bottom;
First disconnect the battery.
Remove four screws on each side front grill.
Open bonnet and remove the “Rubber band” and rear Headlamp buckets, this helps get
access to the hook/nut that holds the grill into the wing. These often break so be careful.
Ease plug off main bulb and side light below main bulb and pull wires out the way.
Mark from the front position of old unit so new unit will go exactly in the same place.
You can now gain access to the nut holding the grill in the front panel.
Loosen all four 8MM nuts, don’t let old unit drop out the front and when refitting new unit.
Lift old unit away and store out the way.
Clean front panel before refitting new units as this is the best chance you’ll get, see the
difference before and after.
Before fitting new unit it is easier to refit the bulbs (or new bulbs) then offer up new unit to
panel and hold in place whilst bolting loosely into place.
Adjust unit in correct position so grill doesn’t foul unit and the lamp is central (where you
previously marked it).
Once happy with position tighten four bolts to secure unit in place.
Connect side light connectors and main bulb connector.
Refit front grills with four screws and the hook. Carefully position hook through hole in front
panel and secure with nut.
Refit headlamp buckets with rubber band.
Reconnect battery and check all lights work.
All that remains now is to pop down your local MOT testing station and adjust rear screws to
align beam correctly.
Look at final unit, I also fitted new front grills, so the whole front end looks fresh and new.